Container



April 22, 1969 D. D. OVERTON Ill, ETAL CONTAINER Sheet of 5 Filed Jan. 5. 1968 DOLPHIN o. -ovERToN,III

RUDOLPH B. RUSTIN,JR.

WILLIAM E. HUGHES BYZ- Q fiendusm ATTORNEYS April 1969 D. D. OVERTON m, ETAL 3,439,862

CONTAINER Filed Jan. 5, 1968 Sheet 2 of 3 INVENTORS DOLPHIN D. OVERTON, Ill RUDOLPH B.RUSTIN,JR. WILLIAM E. HUGHES Emeyan (Q '/wlmsfin ATTORNEYS United States Patent US. Cl. 229--23 12 Claims ABSTRACT OF THE DISCLOSURE A strong, rectangular, reinforced, tobacco container is provided that presents an effective barrier to foreign ob jects and presents smooth interior wall surfaces. A foldable shell forms the outer bottom, side, and top walls for the container. Cleats are attached to the inner surface of the side and bottom walls at each end of these walls. Two end sections are provided that each include a panel and a frame with the peripheral edge of the panel extending beyond the frame to form lips on the top, bottom, and side edges of the end section. In the assembled container, the cleats attached to the side and bottom walls abut the side and bottom lips of the end section and the side and bottom edges of the frame of the end section. The container includes a reinforcing bottom member, and a reinforcing top member. The reinforcing top member has depending cleats which abut the top lip portion of the end panel and the top edge of the frame. Securing means hold the shell and the reinforcing top member in engagement with the end sections.

This invention relates to containers. More particularly, this invention relates to containers that may be rapidly assembled from a flat, knocked-down condition, that are capable of providing sealing contact between outer elements of the containers, and that have sufiicient strength to be stacked one on top of the other without damage to the container even when filled with a heavy load.

The containers of the invention are particularly well suited to be used as protective containers for tobacco shipped overseas in moisture-impermeable plastic liners. Throughout the specification, numerous references will be made to the use of the containers as tobacco cases, and certain prior art tobacco cases will be discussed. However, it should be realized that the invention could be used in the pacakaging of other materials as well as tobacco.

In the design of containers for shipped export tobacco, a prime consideration is to ensure that water vapor and moisture are not absorbed by the tobacco during shipment. The tariff on tobacco shipped to foreign countries is high; for example, England levies a tariff of $11 per pound on tobacco. It can be seen that the absorption of even small amounts of moisture during overseas shipment can cause increased weight and result in greatly increased costs.

When Water-impermeable plastic liners are used with tobacco containers to prevent moisture from being absorbed into the tobacco, the liners should be placed in containers having smooth interior surfaces, since sharp interior projections on the inside of a container may penetrate the liner during handling of the container and permit moisture or foreign matter to reach the tobacco.

Problems have been encountered in attempting to provide protective containers which can be used in conjunction with the plastic liners.

The assembly of wooden containers using nails is one such problem. Inwardly projecting nails or splinters of wood caused by nailing are capable of penetrating and "ice destroying the moisture-impermeable barrier of a film liner. Consequently, wooden boxes which require nailing during the final assembly operations by the user of the container have not proved to be desirable.

Corrugated paperboard containers have also been used to package tobacco. However, such containers have not been well suited for stacking on top of each other. In shipping tobacco overseas, filled containers weighing from 450 to 500 pounds have been found desirable for handling purposes. The size of these containers makes it desirable that the containers be stacked on top of each other in piles 8 to 10 containers high during shipment. Stacking of prior paperboard containers to this height has not been practical since the accumulated weight of the stack tends to damage the lower containers.

A container that encloses a quantity of tobacco or other product desirably prevents entry of small foreign objects into the interior of the container. In containers that have a moisture impermeable liner, it is important that the container prevent entry of foreign matter that could puncture the plastic liner. Therefore, the presence of a plastic inner liner does not remove the requirements that a tobacco export container (a) be capable of being easily and tightly sealed, and (b) be capable of remaining tightly sealed during the normal impacts that may be received during stacking and transporting of thefilled containers.

Accordingly, it is a primary object of this invention to provide a new and improved container.

It is a further object of this invention to provide new and improved containers that are capable of being stacked on top of each other without crushing even when filled with a heavy load.

A still further object of this invention is to provide a new and improved container that may be easily and tightly sealed against entry of foreign matter.

Another object of the invention is to provide a new and improved container having smooth interior surfaces.

Yet another object of this invention is to provide a new and improved container that may be rapidly assembled and disassembled by unskilled labor.

Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

To achieve the foregoing objects and in accordance with the purpose of the invention, as embodied and broadly described herein, the container of this invention comprises a foldable shell including a bottom panel, a pair of side panels, and at least one flap for forming a top for the container; cleats attached across the inner surfaces of each end of the bottom and side panels; two (2) end sections each including a substantially rectangular end panel and a substantially rectangular frame secured to the outer surface of the panel With the frame being slightly smaller than the end panel to provide top, bottom, and side lips, each of the lips comprising the portion of said panel extending beyond the frame, the end panel being positioned inwardly of the cleats in the assembled container with the cleats abutting the bottom and side lips of each of the end sections and with the inner edges of the cleats abutting the outer peripheral edges of the frame; a reinforcing top member positioned within the shell and having a depending cleat attached across each end, the top member being supported by the end sections, with the depending cleats abutting the top lips of the end sections and the outer edge of the tops of the frames to permit transfer of downward compressive force from the top member to the end sections; and means for securing the shell to the end sections.

Preferably the shell includes two flaps with a flap attached to the upper edge of each side panel and with the width of the flaps permitting the flaps to be folded inwardly into an overlapping relationship.

It is also preferred that the securing means include slots in the top, bottom, and sides of the frame of each of the end sections, grooves in the cleats on the bottom panel, side panels, and the top member that are aligned with the slots in the frame, and fastening means for insertion through the slots and the grooves.

It is also preferred that the container have a reinforcing bottom member positioned on the bottom panel to provide a strong bottom for the container.

The invention consists in the novel parts, constructions, arrangements, combinations and improvements shown and described. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate One embodiment of the invention and, together with the description, serve to explain the principles of the invention.

Of the drawings:

FIG. 1 is a perspective view of an assembled container constructed in accordance with the teachings of this invention;

FIG. 2 is an exploded perspective view of the container of FIG. 1 but with the tie wires and steel banding omitted;

FIG. 3 is a top plan view of the shell of the container of FIG. 1 showing the position of the cleats on the ends of the wall panels;

FIG. 4 is a sectional view taken along line 44 of FIG. 1; and

FIG. 5 is a sectional view taken along line 55 of FIG. 1.

Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.

Referring now to FIGS. 1 and 2, it may be seen that thecontainer is a tobacco case useful for shipping tobacco overseas. The container includes a foldable shell, generally 10, having a bottom panel 12 and a pair of side panels 14 and 15.

In accordance with the invention, the foldable shell also includes at least one flap for providing an outer top wall surface for the container. As here embodied, two flaps 16 and 18 are provided with extend from the top edge of the side panels 14 and 15, respectively. Preferably, the width of each of flaps 16 and 18 exceeds onehalf the width of bottom panel 12 to permit folding the flaps into an overlapping relationship with an overlapped strip extending longitudinally along the center of the top surface of the container.

As shown in FIG. 3, score lines 20 and 21 separate the bottom panel 12 from the side panels 14 and 15, and score lines 24 and 25 separate side panels 14 and from flaps 16 and 18. Each of the side panels 14 and 15, and bottom panel 12, includes a pair of holes 26 and 27. Each hole is preferably transversely centered on its respective panel and is positioned a short distance inwardly from the end edge of the panel. Flaps 16 and 18 each include a pair of holes 28 and 29 that are positioned inwardly of the end edges of the flaps a distance which corresponds to the inward spacing of holes 26 and 27. The holes 28 and 29 are positioned to be vertically aligned when flaps 16 and 18 are folded inwardly into a horizontal overlapping position.

Preferably, shell 10 is of a rectangular configuration and score lines 20, 21, 24, and 25 extend perpendicularly to the longitudinal edges of the blank so that the bottom panel, the side panels, and the flaps all have a rectangular shape. The shell is preferably made of corrugated paperboard or fiber-board, but may be of any material which possesses suitable puncture, compression, and bursting strength.

In accordance with the invention, a plurality of cleats are attached to the ends of the shell to strengthen the container and to cooperate with the end panels in sealing the ends of the container. As best illustrated in FIGS. 2 and 3, cleats 36 and 37 are attached to the ends of the inside surface of bottom panel 12, cleats 38 and 39 are attached to the ends of the inside surface of side panel 14, and cleats 41 and 43 are attached to the ends of the inside surface of side panel 15. Preferably, each of the cleats extends the width of the panels to which they are attached and includes mitered ends to permit the lower edges of cleats 38 and 41.to abut the edges of cleat 36 in miter joints and the lower edges of cleats 39 and 43 to abut the edges of cleat 37 in miter joints.

Grooves are provided on the inner faces of each of cleats 36, 37,, 38, 39, 41, and 43 to facilitate securing the container by fasteners, as will be more fully discussed below, and to prevent tearing of the shell by the fasteners. Cleats 36. and 37 each include a groove 42 extending vertically from the bottom panel 12, and cleats 38 and 39 of side panel 14 and cleats 41 and 43 of side panel 15 each include a groove 44 extending inwardly from the inner surface of the side panel across the width of the cleats.

Preferably the cleats are positioned on their respective panels with the outer side face of the cleat aligned with the end edge of the panel. A groove 42 is aligned with holes 26 and 27 in the bottom panel and a groove 44 is aligned with each hole in the side panels. The cleats are preferably stapled to the shell 10. Reinforcing filament type may be attached to the ends of bottom panel 12 and side panels Hand 15 to prevent the staples from tearing the shell. The cleats may be of wood or other suitable material.

In accordance with the invention, a pair of substantially identical end sections, generally and 52, are provided that cooperate with cleats attached to the side and bottom panels of the container and cleats attached to a top reinforcing member to provide strong containers that may be stacked one on top of the other. The two end sections each include a rectangular end panel and a rectangular frame of substantially uniform thickness secured to one side of the end panel with the frame being slightly smaller than the end panel to provide a lip comprising a portion of the end panel extending along each edge of the end section. The term lip as used herein refers to a projecting edge of the end panel. Since end sections 50 and 52 are substantially identical, only end section 50 will be described in detail.

As here embodied, and as best seen in FIGS. 1 and 2, the end section, generally 50, comprises a rectangular panel 54 with a rectangular frame, generally 56, mounted on its outside surface. Frame 56 may be secured to panel 54 in any suitable manner as by staples or wire stitches (not shown) on the inside of panel 54 and extending into frame 56. Preferably, the means for attaching frame 56 to panel 54 are such that no sharp points extend out of the inside of the panel or out of the outside of the frame.

Frame 56 is comprised of two horizontal battens 58 and 60 and two vertical battens 62 and 64. Preferably, the battens are all the same thickness so that the frame has a uniform thickness.

As may be seen in FIG. 2, end section 50 includes lips 66, 68, 70, and 72 extending along each edge of the end section. The lips are formed by the portion of panel 54 which extends beyond the edges of frame 56. Preferably, the top and bottom lips 66 and 68 are of the same width and thickness, and the two side lips 70 and 72 are of the same width and thickness. This uniformity of dimension permits ease of assembly, since the end sections will have no arbitrary top or bottom and can be used in either position without affecting the remainder of the assembly. As here embodied, all four of the lips are of the same width and thickness and the end section 50 is square so that it can be used in any position without affecting the remainder of the assembly. The distance lips 68, 70, and 72 extend beyond the edge of frame 56 preferably is made substantially equal to the distance that cleats 36, 38, and 41 respectively, project from their respective panels.

A plurality of slots 74, best shown in FIG. 2, are provided in frame 56 adjacent panel 54. One slot is centrally located along the length of each batten 58, 60, 62, and 64.

As shown in FIGS. 2, 4, and 5, a reinforcing bottom member 80 is provided to strengthen the bottom of the container. Preferably, the width of bottom member 80 is slightly smaller than the width of bottom panel 12, and the length of bottom member 80 is slightly less than the length of bottom panel 12 minus the combined thickness of the two cleats 36 and 37 on the bottom panel and the two end panels 54 of end sections 50 and 52. This size permits bottom member 80 to be positioned on bottom panel 12 between end sections 50 and 52. The bottom member may be of plywood or other strong lightweight material that irnparts strength to the bottom of the container.

In accordance with the invention, a top member having depending cleats is provided that allows transfer of the weight of a package or other article placed on top of the container to the end sections 50' and 52-, and cooperates with flaps 16 and 18 to form a seal at the top of the end sections. As here embodied, and as seen in FIGS. 2 and 4, the top member, generally 82, includes a rectangular panel 84 and a pair of depending cleats 86 and 87. A pair of holes 88 and 89 are provided in panel 84 with one hole at each end thereof, and depending cleats 86 and 87 each include grooves 90 therein, best seen in FIG. 5. Each hole 88 and 8 9 is vertically aligned with a groove 90.

Preferably, panel 84 is the same length as bottom panel 12 of shell and the width of panel 84 approximates the distance between side panels 14 and 15. Panel 84 thus extends the length of the container and may be supported by the upper edges of the end panels 54 of end sections and '52.

Depending cleats 86 and 87 extend the width of panel 84 and are attached at each end of the panel 84 by suitable means, such as nails (not shown). Preferably, cleats 86 and 87 have mitered ends so that they form a miter joint with the top end 92 of each of the cleats on side panels 14 and 15. The height of cleats 8 6 and 87 is desirably the same as the height of the top lip 66 of the end sections. Thus, the bottom edges of cleats 86 and 87 are supported by the top edge of horizontal battens of end sections 50 and 52.

In accordance with the invention, means are provided for securing the shell to the end sections in such a manner that the container will be sealed against entry of foreign matter and substantially sealed against entry of moisture. As here embodied, the securing means consist of the holes 26, 27, 28, and 29 in shell 10, the grooves 42 and 44 in the cleats attached to the shell, the slots 74 in the frames 56 of end sections 50 and 52, and fastening means which are preferably tie wires 76. One end of the tie wires 76 passes through the aligned holes, grooves, and slots as will be described in more detail hereinafter to hold the end sections 50 and 52 to the shell 10.

As here embodied, four (4) tie wires 76 are used at each end of the container. It will be readily appreciated by those skilled in the art that more tie wires could be used with additional holes and slots, if desired. The securing means may also include tying means, such as band 100 and 162, made of steel or other suitable material, which may be wrapped laterally around the container and secured to themselves to firmly hold the container in the assembled position.

Preferably, a container manufacturer prefabricates the various elements of the container. The elements of the container may then be shipped to the user in a knockeddown condition for assembly by the user to provide economical utilization of shipment and storage space. The container manufacturer would, for example, preferably score shell 10, attach cleats 3-6, 37, 38, 39', 41 and 43 to the shell, and attach the frame 56 to panel 54 of end sections 50 and 52, but would not attach the end sections to the shell.

To assemble the container at its place of use, end sections 50 and 52 are placed on bottom panel 12 with each frame 56 facing outwardly and with each panel 54 positioned inwardly of the cleats 36 and 37 of the bottom panel. The bottom lip 68 of end sections 50 and 52 is positioned to abut the inside surfaces of the cleats 36 and 37 at each end of the bottom panel.

To secure end section 50 to bottom panel 12, one end of a tie wire 76 is inserted through hole 2 6 in the bottom panel, through groove 42 in cleat 36, and through the aligned slot 74 that extends through batten 58. The other end of the tie wire extends around the outside edge of cleat 36 and batten 58. The ends of the tie wire are secured by twisting them together and are pushed against panel 54 as shown in FIG. 1. End section 52 is secured to bottom panel 12 in a similar manner.

If desired, the tie wire may be first only inserted through the holes, grooves, and slots of the various members, and then twisted together after the sides of the container have been positioned relative to the end section.

After the end sections 50 and 52 are in place, side panels 1 4 and 15 are folded into vertical position with the inner side face of cleats 38 and 41 of side panels 14 and 15 abutting the side of lips 70 and 72 of end section 50 and the inner side face of cleats 39 and 43 of the side panels 14 and 15 abutting the sides of lips 70 and 72 of end section 52. The edge of cleats 38 and 41 abut the edges of battens 62 and 64, respectively, of end section 50, and the edge of cleats 39 and 43- abut the edges of the battens 62 and 64 of end section 52. The mitered bottom ends 40 of cleats 38 and 41 are positioned on the mitered ends of cleat 36 to form a miter joint.

When side panels 14 and 15 are in position, one end of a tie wire 76 is inserted through holes 26 in side panels 14 and 15, through the aligned grooves 44 in cleats 38 and 41, and through the aligned slots 74 in frame 56 of end section 50. The other ends of these tie wires are in each case extended around one of cleats 38 and 41 and a vertical batten 62 or 64. The ends of the tie wires are secured by twisting and are pushed against the panel 54 as shown in FIG. 1. Side panels 14 and 15 are secured to end section 52 in a similar manner.

Bottom member 80 may be positioned on bottom panel 12 prior to positioning of the end sections, after positioning of the end sections, or after assembly of the end sections and the side panels of the container.

With bottom member 80 in place, the container is ready for loading. If the container is to be used to transport export tobacco, a plastic liner 96, as shown in FIGS. 4 and 5, is inserted into the container. This liner is preferably shaped to conform to the interior of the container. The container is then filled with tobacco. After filling the liner with tobacco, the tobacco is usually pressed. Next, the top of the liner is closed and sealed by a conventional procedure, such as heat scaling, to form a moisture-impermeable barrier. After the container is loaded, top member 82 is placed on end sections 50 and 52 with the lower surface of panel 84 resting on the top edge of each of end panels 54. The inner surface and lower edge of the cleats 86 and 87 abut the outer surface of top lips 66 and the upper edge of battens 60 respectively, of each of the end sections 50 and 52. The mitered ends of cleat 86- rest on top ends 92 of cleats 38 and 41 in flush contact therewith and the mitered ends of cleat 87 rest on cleats 39 and 43 in similar fashion.

After the top member is in place on the container, flaps 16 and 18 are folded into a horizontal position with the edge of flap 18 overlapping the edge of flap 16, and with the two holes 28 and the two holes 29 vertically aligned.

When flaps 16 and 18 are folded into place, tie wire 76 may be inserted through each of the holes 28 in the flaps, through hole 88 in top panel 84, through groove 90 in depending cleat 86, and through slot 74 in horizontal batten 60. The other end of the tie wire 76 is extended over the ends of flaps 1-6 and 18, and along the outer surfaces of cleat 86 and batten 60. The two (2.) ends of the tie wire 76 are then twisted together and pushed against panel 54. A second tie wire is then secured in a similar manner to the other end to secure the flaps and top member to end panel 52.

In this condition the container has sufiicient strength to be moved by conveyors and other means, if desired. Preferably, however, the container is further secured with tying means, such as steel straps, placed around the container.

Referring to FIG. 1, it may be seen that tying means, here illustrated as two (2) steel straps 100 and 102, have been placed laterally around the container.

The invention provides containers that may be easily assembled and tightly sealed against entry of foreign matter and that may be stacked on top of each other when filled with heavy material without damage to the container or its contents.

It will be apparent to those skilled in the art that various modifications and variations could be made in the containers of the invention without departing from the scope or spirit of the invention.

What is claimed is:

1. A container comprising:

(a) a foldable shell including a bottom panel, a pair of said panels, and at least one flap for forming a top for the container;

(b) cleats attached across the inner surfaces of each end of said bottom panel and said side panels;

(c) two end sections, each of said end sections including a substantially rectangular end panel and a substantially rectangular frame secured to the outer surface of said panel, the periphery of said frame being slightly smaller than the periphery of said end panel to provide top, bottom, and side lips, each of said lips comprising the portion of said panel extending beyond said frame, said end panel being positioned inwardly of said cleats in the assembled container with said cleats abutting the bottom and side lips of each of said end sections and with the inner edges of said cleats abutting the outer peripheral edge of said frame;

(d) a reinforcing top member positioned within said shell and having a depending cleat attached across each end, said top member being supported by said end sections, with said depending cleats abutting the top lips of said end sections and the outer edge of the tops of said frames to permit transfer of downward compressive force from said top member to said end sections; and

(e) securing means for attaching said shell to said end sections.

2. The container of claim 1 wherein said shell includes two flaps, with a flap attached to the upper edge of each side panel, and wherein the width of said flaps permits said flaps to be folded inwardly into overlapping abutting relationship.

3. The container of claim 2 wherein said securing means includes slots in the top, bottom, and sides of said frame of each of said end sections; grooves in said cleats on said bottom and side panels and said top member that are aligned with said slots in said frame; and fastening means for insertion through said slots and said grooves.

4. The container of claim 3 wherein said side and bottom panels and said flaps include holes aligned with said grooves to facilitate the insertion of fastening means through said shell.

5. The container of claim 1 including a reinforcing bottom member positioned on said bottom panel.

6. The container of claim 5 wherein a flap is attached to the upper edge of each of said side panels, and wherein the width of each of said flaps exceeds one-half the Width of the container to permit overlapping said flaps along the longitudinally extending center line of the top surface of the container.

7. The container of claim 5 wherein said securing means includes slots in the top, bottom, and sides of said frame of each of said end sections; grooves in said cleats on said bottom panel, side panels, and said top member that are aligned with said slots in said frame; and fastening means for insertion through said slots and said grooves.

8. The container of claim 7 wherein said shell includes two flaps and said side and bottom panels and said flaps include holes aligned with the grooves in said cleats to facilitate the insertion of fastening means through said shell.

9. A container comprising:

(a) a foldable fiberboard shell including a bottom panel, a pair of side panels, and a pair of flaps with one flap attached to the upper edge of each said panel, the width of said flaps each exceeding one half the width of the container to permit said flaps to form an overlapping strip when said flaps are folded inwardly into a horizontal position, said panels each including a pair of holes with one hole positioned along each end of the panel, said flaps each including a pair of holes that are vertically aligned when said flaps are folded into a horizontal overlapping position;

(d) cleats attached across the inner end surfaces of said bottom panel and said side panels, said cleats having mitered ends that are adjoining when said side panels are folded into vertical position and including grooves extending perpendicularly from the panels to prevent tearing of said panels by tie wires inserted through said panels and through said grooves;

(0) two end sections positioned on said bottom panel, each of said end sections including a rectangular panel and a rectangular frame secured to the outer surface of said panel, said frame including slots on its bottom and said edges that are aligned with said grooves in said cleats, and a slot on its top edge, said end panel being positioned inwardly of said cleats in the assembled container with cleats abutting the bottom and side lips of each of said end sections and with the inner edges of said cleats abutting the outer peripheral edge of said frame;

((1) a reinforcing top member including a top panel and a pair of depending cleats, the depending cleats attached across each end edge of said top panel, said depending cleats each including a vertical groove, aligned with the holes in said flaps and the slot in the top edge of said frame, said top panel including a pair of holes with each hole aligned with one of said vertical grooves, said top member supported by said end sections with each of said depending cleats abutting the top lip of said end section and the top edge of said frame of one of said end sections to permit transfer of downward compressive force from said top member to said end sections; and

(e) means for fastening said shell and said top member to said end sections, said means including wire fasteners passing through said holes in said side and bottom panels, through said grooves in said cleats, and through said slots in the side and bottom edges of said frame for securing said side and bottom panels to said end sections, and wire fasteners passing through said holes in said flaps, said holes in said top member, said grooves in said depending cleats and said slots in the top edge of said frame for securing said flaps and said top member to said end sections.

10. The containers of claim 9 wherein said fastening means comprise a plurality of tie wires with tie wires provided for each aligned set of holes, grooves, and slots, with a first end of some tie wires inserted through holes in said panels, through adjacent grooves in said cleats, and through the adjacent slots in said frame, with a first end of other tie wires inserted through the vertically aligned holes of said flaps, through adjacent holes in said top member, through adjacent grooves in said depending cleats and through adjacent slots in the top edge of said frame, with the other end of each of the tie wires extending around the outside of said cleats and said frame and secured to the first end of the tie wires.

11. The container of claim 10 including a reinforcing bottom member positioned on said bottom panel.

12. The container of claim 10 including tying means extending laterally abut the container for firmly holding the container in assembled position.

References Cited DAVID M. BOCKENEK, Primary Examiner.

US. Cl. X.R. 

